Valve assembly for an electronic faucet

ABSTRACT

An electronic faucet includes a spout, a fluid supply conduit supported by the spout, and a valve assembly including an electrically operable valve. A controller is coupled to the valve assembly and includes a processor operative to control the electrically operable valve to control fluid flow through the fluid supply conduit. The controller includes a port in communication with the processor, the port being releasably coupled to electronics of a secondary device.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation application of U.S. patentapplication Ser. No. 15/247,378, filed Aug. 25, 2016, which is adivisional application of U.S. patent application Ser. No. 13/837,052,filed Mar. 15, 2013, the disclosures of which are expressly incorporatedherein by reference.

BACKGROUND AND SUMMARY

The present disclosure relates generally to a fluid delivery apparatus.More particularly, the present disclosure relates to an integratedsolenoid valve assembly for an electronic faucet.

Electronic faucets typically include a solenoid valve controlled by anelectronic controller for controlling fluid flow. Some electronicfaucets include proximity sensors such as active infrared (“IR”)proximity detectors or capacitive proximity sensors to control operationof the solenoid valve. Such proximity sensors are used to detect auser's hands positioned near the faucet and to automatically start fluidflow through the faucet in response to detection of the user's hands.Other electronic faucets use touch sensors to control the faucet.

The electronic controller is typically located away from the solenoidvalve, and electrical wires are routed between the solenoid valve andthe electronic controller for controlling the solenoid valve. Additionalwire terminations are often made between the solenoid valve and theelectronic controller depending on the configuration of the faucetsystem. The wiring and associated wire connections add cost to theelectronic faucet as well as additional circuit components susceptibleto damage or failure.

Some electronic faucets include temperature sensors positioned withinthe solenoid valve housing to detect the temperature of the water in thehousing. The temperature sensor is often encapsulated in an epoxy-filledcasing, and the casing is sealed and placed in the waterway of the valvehousing. A wire is routed from the temperature sensor in the casing tothe controller outside of solenoid valve housing. The sensor casing andwiring interfaces are often susceptible to damage and/or leaking,thereby damaging the temperature sensor and wiring. Further, theencapsulated sensor, the routed wiring, and associated wire connectionsadd cost and complexity to the electronic faucet.

In bathrooms and kitchens with multiple electronic faucets and/or otherdispensing devices, each dispensing device includes a controller forcontrolling the respective device. Such a system is costly due to themultiple processors and other control electronics required to controleach dispensing device.

According to an illustrative embodiment of the present disclosure, anelectronic faucet is provided including a spout, a fluid supply conduitsupported by the spout, and a valve assembly. The valve assemblyincludes a solenoid valve positioned to control fluid flow through thefluid supply conduit. The solenoid valve includes a solenoid coil and amoveable valve member operably coupled to the moveable valve member. Thefaucet further includes a controller operative to control the solenoidvalve. The controller includes a circuit board coupled to the valveassembly and a processor mounted to the circuit board to control thesolenoid valve. The solenoid coil is mounted to the circuit board.

According to another illustrative embodiment of the present disclosure,an electrically operable valve assembly for an electronic faucet isprovided. The valve assembly includes a valve housing having an interiorregion for receiving a fluid. The valve assembly further includes asolenoid valve, a temperature sensor positioned outside the interiorregion, and a heat transfer device. The heat transfer device extendsbetween the temperature sensor and the interior region to transfer heatfrom fluid in the interior region to the temperature sensor. The valveassembly further includes a controller in communication with thetemperature sensor. The controller is operative to control the solenoidvalve.

According to yet another illustrative embodiment of the presentdisclosure, an electronic faucet is provided. The faucet includes aspout, a fluid supply conduit supported by the spout, and a valveassembly including an electrically operable valve positioned to regulatefluid flow through the fluid supply conduit. The faucet includes acontroller coupled to the valve assembly. The controller includes aprocessor operative to control the electrically operable valve tocontrol fluid flow through the fluid supply conduit. The controllerincludes a port in communication with the processor. The port isreleasably coupled to electronics of a secondary device. The controlleris operative to at least one of control and power the electronics of thesecondary device via the port.

According to still another illustrative embodiment of the presentdisclosure, a faucet assembly is provided. The faucet assembly includesan electronic faucet and a secondary dispensing device. The electronicfaucet includes a spout, a fluid supply conduit supported by the spout,and a valve assembly including an electrically operable valve positionedto regulate fluid flow through the fluid supply conduit. The electronicfaucet further includes a controller operative to control theelectrically operable valve to control fluid flow through the fluidsupply conduit. The controller includes a port. The controller and theport are mounted to the valve assembly. The secondary dispensing deviceincludes a spout, a fluid supply conduit supported by the spout, andelectronics operably coupled to the port of the controller of theelectronic faucet. The controller of the electronic faucet is operativeto at least one of control and power the electronics of the secondarydispensing device via the port to control fluid flow through the fluidsupply conduit of the secondary dispensing device.

Additional features and advantages of the present invention will becomeapparent to those skilled in the art upon consideration of the followingdetailed description of the illustrative embodiment exemplifying thebest mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description of the drawings particularly refers to theaccompanying figures in which:

FIG. 1 is a block diagram illustrating an exemplary electronic faucetincluding a solenoid valve;

FIG. 2 is a block diagram illustrating an exemplary controller of theelectronic faucet of FIG. 1;

FIG. 3 is a perspective view of an exemplary solenoid valve assembly ofthe electronic faucet of FIG. 1 including an outer housing;

FIG. 4 is a perspective view of the solenoid valve assembly of FIG. 3with the outer housing removed;

FIG. 5 is a partially exploded perspective view of the solenoid valveassembly of FIG. 3 illustrating a solenoid coil, a controller, and atemperature sensor;

FIG. 6 is a partially exploded reverse perspective view of the solenoidvalve assembly of FIG. 3 illustrating the solenoid coil, the controller,and the temperature sensor;

FIG. 7 is a cross-sectional view of the solenoid valve assembly of FIG.3 taken along line 7-7 of FIG. 3;

FIG. 8 is a close-up of the cross-sectional view of FIG. 7 with anarmature of the solenoid coil in a closed position;

FIG. 9 is a close-up of the cross-sectional view of FIG. 7 with thearmature of the solenoid coil in an open position; and

FIG. 10 is a cross-sectional view of the solenoid valve assembly of FIG.3 taken along line 10-10 of FIG. 3 illustrating a flow path through thesolenoid valve assembly.

DETAILED DESCRIPTION OF THE DRAWINGS

For the purposes of promoting an understanding of the principles of thepresent disclosure, reference will now be made to the embodimentsillustrated in the drawings, which are described herein. The embodimentsdisclosed herein are not intended to be exhaustive or to limit theinvention to the precise form disclosed. Rather, the embodiments arechosen and described so that others skilled in the art may utilize theirteachings. Therefore, no limitation of the scope of the claimedinvention is thereby intended. The present invention includes anyalterations and further modifications of the illustrated devices anddescribed methods and further applications of the principles of theinvention which would normally occur to one skilled in the art to whichthe invention relates.

Referring to FIG. 1, a block diagram of an electronic faucet 10 isillustrated according to some embodiments of the present disclosure.Electronic faucet 10 includes a spout 12 supporting a passageway orfluid conduit for delivering fluids such as water, for example. In theillustrated embodiment, the passageway of spout 12 includes fluidpassages between hot and cold water sources 16, 18 and the output ofspout 12. See, for example, passages 28 a, 28 b, 28 c, 28 d of FIG. 1.Electronic faucet 10 includes a solenoid valve 22 in fluid communicationwith hot and cold water sources 16, 18. Solenoid valve 22 is controlledelectronically by a controller 24. In the illustrated embodiment,controller 24 is configured to open and close solenoid valve 22 to turnon and off the fluid flow to spout 12. In another embodiment, controller24 is further configured to proportionally control solenoid valve 22 toadjust the flow rate of the fluid flowing through spout 12. In anillustrative embodiment described herein, solenoid valve 22 includes apilot operated solenoid valve, although another suitable electricallyoperable or actuator driven valve may be provided.

In the illustrated embodiment, controller 24 controls solenoid valve 22based on output from at least one sensor, such as a proximity sensorand/or a touch sensor, for example, to turn on and off fluid flowthrough spout 12. In the illustrated embodiment, a capacitive sensor 26is in communication with controller 24 for providing signals tocontroller 24 indicating the detection of an object (e.g. a user'shands) on or near spout 12. Other suitable sensors may be provided fordetecting an object near faucet 10. As illustrated, an electrode 25 ofcapacitive sensor 26 is coupled to spout 12 to detect the objectcontacting spout 12. Electrode 25 may be positioned in other suitableareas of faucet 10 for detecting the presence of a user's hands. In theillustrative embodiment, capacitive sensor 26 and electrode 25 are usedfor at least one of a touch mode and a hands-free mode of operation. Inthe hands free mode of operation, capacitive sensor 26 and controller 24detect a user's hands or other object within a detection area or zonenear spout 12. In one embodiment, the detection area includes the waterstream and the area in the sink basin immediately surrounding the waterstream. The detection area may be expanded to other areas depending onthe location and sensitivity of capacitive sensor 26. In the touch modeof operation, capacitive sensor 26 and controller 24 detect a user'shands or other object upon contact with a surface of spout 12. To turnon the faucet assembly 10 in either mode, solenoid valve 22 is activatedby controller 24 upon detecting the object (e.g., user's hands) totoggle water flow on and off.

In some embodiments, by sensing capacitance changes with capacitivesensor 26, controller 24 is configured to make logical decisions tocontrol different modes of operation of faucet 10 such as changingbetween a manual mode of operation and a hands free mode of operation asdescribed in U.S. Pat. No. 7,537,023; U.S. Pat. No. 7,690,395; U.S. Pat.No. 7,150,293; U.S. Pat. No. 7,997,301; and PCT InternationalApplication Serial Nos. PCT/US2008/01288 and PCT/US2008/013598, thedisclosures of which are all expressly incorporated herein by reference.

In one embodiment, manual adjustment of the water temperature and flowrate may be provided after opening the solenoid valve 22 by manipulatinga manual valve handle 14. In particular, manual valve handle 14 may beused to manipulate a valve body assembly 20 positioned in the passagewayof spout 12 to adjust the temperature and/or flow of fluid from the hotand cold water sources 16, 18 to solenoid valve 22. A separate manualvalve handle 14 may be provided for each of the hot and cold watersources 16, 18. Alternatively, electronic faucet 10 is a fully automaticfaucet without any manual controls.

In an alternative embodiment, controller 24 may further control valvebody assembly 20 electronically. In particular, valve body assembly 20may include an electronic proportioning or mixing valve that is adjustedby controller 24 to control the mixture of hot and cold water and thusthe temperature of the water flowing through spout 12. Exemplaryelectronically controlled mixing valves are described in U.S. Pat. No.7,458,520 and PCT International Application Serial No.PCT/US2007/060512, the disclosures of which are expressly incorporatedby reference herein. The amount of fluid flowing from hot water source16 and cold water source 18 may be controlled by controller 24 based onone or more user inputs, such as desired fluid temperature, desiredfluid flow rate, desired fluid volume, various task based inputs,various recognized presentments, and/or combinations thereof. Forexample, faucet 10 may include a temperature sensor (e.g., temperaturesensor 54 described herein) in fluid communication with the output ofthe proportioning valve to provide feedback to controller 24 for use incontrolling the water temperature. In one embodiment, controller 24controls the proportional valve via the auxiliary port 56 (FIG. 2)described herein.

In one embodiment, faucet 10 includes one or more indicators 29controlled by controller 24 to provide a visual or audio indication ofthe operational mode (e.g., hands free and/or touch mode) and/or watertemperature of the electronic faucet 10. An exemplary indicator 29includes a light-emitting diode (LED) or other light source or audibledevice positioned near faucet 10. Other exemplary indicators 29 includea liquid crystal display (LCD) and a magnetically latching mechanicalindicator. In one embodiment, indicators 29 are operative to indicateoperating mode and/or the temperature of the water flowing throughfaucet 10 based on the selective illumination of different colored LED'sor a single multi-colored LED.

In the illustrated embodiment, controller 24 is operative to controlanother remote or secondary device in addition to electronic faucet 10,illustratively auxiliary dispensing device 30. An exemplary auxiliarydispensing device 30 includes a soap dispenser, another faucet spout, abeverage dispenser, or another suitable dispensing device. Auxiliarydispensing device 30 may be positioned adjacent the same sink basin asspout 12. Alternatively, dispensing device 30 may be positioned todispense into a different sink basin, such as another sink basin in abathroom or kitchen or in another room, for example. As described indetail herein, controller 24 illustratively includes an auxiliary port56 (see FIGS. 2 and 3) for remotely controlling and powering theauxiliary dispensing device 30 via a cable 57 (FIG. 2).

Referring to FIG. 2, a block diagram of an exemplary controller 24 ofFIG. 1 is illustrated. Controller 24 includes a printed circuit board 40and multiple circuit components mounted to the printed circuit board 40.Illustratively, a processor 42, a flow sensor 52, a temperature sensor54, an auxiliary port 56, and a light connector 58 are coupled tocircuit board 40. A connection header 46 is coupled to circuit board 40for coupling a power line from an external power source 21. In oneembodiment, power source 21 is a battery power supply or other directcurrent (DC) power supply. Internal or external memory 44 of processor42 includes software and/or firmware containing instructions executed byprocessor 42 for controlling solenoid valve 22, other components offaucet 10, and other devices (e.g., secondary dispensing device 30).Processor 42 controls solenoid valve 22 based on output from capacitivesensor 26, flow sensor 52, and/or temperature sensor 54.

Light connector 58 is configured to route electrical current to lightdevices 59, such as LED's for example, to illuminate light devices 59.In one embodiment, light devices 59 are different colors, and processor42 selectively controls light devices 59 to illuminate different colorsbased on the operating mode of the faucet 10 and/or the temperature ofthe water flowing through faucet 10. An exemplary light connector 58includes an audio jack connector. In one embodiment, indicators 29 ofFIG. 1 include the light devices 59 of FIG. 2. In the exemplaryembodiment, controller 24 also includes a power connector 48 forcoupling controller 24 to a wall outlet or other building power supplyto power controller 24. Power connector 48 includes a rectifier toconvert alternating current (AC) power to DC power levels suitable forcontroller 24.

Referring to FIGS. 3 and 4, an exemplary solenoid valve assembly 50 isillustrated. Fluid enters a valve housing 70 (FIG. 4) of solenoid valveassembly 50 via fluid conduit 28 c and exits valve housing 70 via fluidconduit 28 d to spout 12 (FIG. 1). Fluid conduit 28 c includes seals 31(FIG. 3) providing a sealing connection to a mating component of thefluid conduit of spout 12. Solenoid valve assembly 50 includes an outerhousing 60 for enclosing and protecting controller 24 and solenoid valve22 positioned within housing 60. Outer housing 60 is configured to slideover the top of valve housing 70 (FIG. 4) and mount to a base 61 ofassembly 50. Clips 72 on opposite ends of base 61 are configured toengage outer housing 60, although other suitable fasteners may be usedto couple outer housing 60 to base 61. Outer housing 60 includes anopening 62 for receiving fluid conduit 28 d. Outer housing 60 furtherincludes an opening 64 that provides access to auxiliary port 56, anopening 66 that provides access to DC power connector 48, and an opening68 that provides access to light connector 58. As illustrated in FIG. 4,controller 24 is mounted to valve housing 70 of assembly 50. A powercable 74 routes power from power source 21 to controller 24 for poweringthe electronic components of controller 24. Power cable 74 includeselectrical wires routed between a connector end 76 configured to coupleto header 46 (FIG. 5) of controller 24 and an opposite connector end 78configured to couple to power source 21. Additional cable wires 75 areprovided to route sensor signals, such as from capacitive sensor 26, tocontroller 24.

Referring to the partially exploded views of FIGS. 5 and 6, processor42, header 46, temperature sensor 54, port 56, DC connector 48, andlight connector 58 are illustratively mounted to printed circuit board40. Port 56, DC connector 48, and light connector 58 are illustrativelymounted at an edge of circuit board 40 to align with openings 64, 66, 68of outer housing 60 (FIG. 3). Circuit board 40 includes other suitableelectronics for controlling solenoid valve 22. Header 46 includeselectrical pins configured to receive connector end 76 of power cable74.

Auxiliary port 56 is configured to receive a connector cable 57 (FIG. 2)routed to an auxiliary or secondary dispensing device 30 (FIG. 2) thatis controlled and powered by controller 24. Connector cable 57 includesa connector that is releasably coupled to auxiliary port 56. As such, aplug-and-play configuration is provided with auxiliary port 56 thatfacilitates quick coupling and decoupling of secondary devices (e.g.,device 30) that are controllable with controller 24 of faucet 10. In oneembodiment, more than one auxiliary dispensing device 30 is coupled toauxiliary port 56 and controlled by controller 24.

Referring again to FIG. 2, the control and power managementsoftware/firmware and control switches of controller 24 are used tocontrol the operation of auxiliary dispensing device 30. Auxiliarydispensing device 30 may include a soap dispenser, another faucet, abeverage dispenser, a filtered water dispenser, a hot water dispenser,or another suitable dispensing device. As illustrated in FIG. 2,auxiliary dispensing device 30 includes a spout 38 that supports a fluidsupply conduit. Dispensing device 30 includes electronics 32 controlledby controller 24 including an electrically operable valve 34, such as asolenoid valve 34 with a solenoid coil, positioned in the fluid supplyconduit for controlling fluid flow through spout 38. Electronics 32 arereleasably coupled to auxiliary port 56 via the quick-coupling connectorcable 57 routed between the faucet 10 and device 30. In one embodiment,fluid flow through the auxiliary dispensing device 30 is controlled byprocessor 42 based on capacitive signals received from device 30 (e.g.,from a sensor 36) via port 56, similar to the capacitive-based controlsof faucet 10. Processor 42 is operative to sample the capacitive inputsignals from auxiliary dispensing device 30 (and/or from additionaldevices 30) to reduce the likelihood of crosstalk between the controlsof electronic faucet 10 and auxiliary dispensing device(s) 30.

Controller 24 routes power received from power source 21 (FIG. 2) or DCconnector 48 to electronics 32 of auxiliary dispensing device 30 viaport 56 to power device 30. As such, in one embodiment, both faucet 10and the auxiliary dispensing device 30 operate off the same power sourceas managed by controller 24. Controller 24 is operative to receiveinputs from auxiliary dispensing device 30, process the inputs, andoutput electrical signals for controlling the electronics 32 (e.g.,solenoid, motor, lights, etc.) of dispensing device 30 based on thereceived inputs. In one embodiment, auxiliary dispensing device 30includes at least one proximity sensor 36, such as a capacitive sensoror infrared sensor, operative to detect a user's hands on or near device30, as similarly described herein with respect to capacitive sensor 26of electronic faucet 10. Alternatively, device 30 may include a switchdevice configured to instruct controller 24 to activate the device 30upon actuation of the switch device by the user. Controller 24 controlsfluid flow (e.g., water, soap, beverage, etc.) through dispensing device30 based on the received signals from the proximity sensor 36 or theswitch device. Controller 24 is also operative to power display lights,such as LED's, on auxiliary dispensing device 30 corresponding to thevarious operational modes or states of device 30.

Accordingly, auxiliary dispensing device 30 may include a passive ordumb electrical interface with limited or no active controls wherein theelectronics 32 of the interface are controlled remotely by controller 24of faucet 10 via auxiliary port 56. In one embodiment, the circuitry ofauxiliary dispensing device 30 includes the necessary circuitry forconnecting the device 30 to controller 24, for detecting and sending anactivation request to controller 24, and for actuating the fluid valvebased on controls from controller 24.

In one example, auxiliary port 56 includes a multi-pin (e.g., 6 pin)registered jack (RJ) receptacle, although any suitable electricalconnector may be used for port 56. In one embodiment, the multiple pinconnections of auxiliary port 56 include a switched power supplyconnected to battery voltage (e.g., power source 21) for poweringelectronics of auxiliary dispensing device 30, a sensor line used aseither an input or output (I/O line) connected to processor 42, a groundline, a proximity (e.g., capacitive) sense input connected to processor42, and two power lines for display lights (e.g., LED's) of device 30.In one embodiment, the LED power lines and the power supply line areswitched on and off at processor 42.

Referring to FIG. 5, temperature sensor 54 is mounted (e.g., soldered)directly to circuit board 40. As such, sensor 54 is positioned outsideof valve housing 70 (see also FIG. 7). In one embodiment, temperaturesensor 54 includes a surface-mount type N thermistor soldered to circuitboard 40, although other suitable temperature sensors may be used. Aheat transfer device 110 extends from temperature sensor 54 to inside aninterior region or waterway 130 (FIG. 7) of valve housing 70. Heattransfer device 110 is operative to transfer heat from the fluid withininterior region 130 of valve housing 70 to temperature sensor 54, asdescribed herein.

Heat transfer device 110 includes a rivet 112 and a pad 114 positionedbetween rivet 112 and sensor 54. In one embodiment, rivet 112 is made ofcopper or another suitable metal, and pad 114 is made of thermallyconductive, electrically insulating foam, although other suitablethermally conductive materials may be used. In assembly, rivet 112, pad114, and sensor 54 are in contact with each other (see FIG. 7) tofacilitate heat transfer. In one embodiment, foam pad 114 provides asoft component between rivet 112 and sensor 54 to reduce the likelihoodthat temperature sensor 54 is damaged due to contact with heat transferdevice 110. Further, pad 114 is electrically insulating such that theelectrical contacts of temperature sensor 54 are not shorted. In oneembodiment, foam pad 114 is coupled to rivet 112 and to circuit board 40over temperature sensor 54 with an adhesive or other suitable coupler.

Referring to FIGS. 5-7, rivet 112 includes a hollow shaft portion 120and a larger diameter head portion 122. As illustrated in FIG. 7, shaftportion 120 extends into the interior region 130 of valve housing 70.Shaft portion 120 is illustratively cylindrical and is configured toreceive water from interior region 130 within the hollow interior. Inone embodiment, the semi-tubular construction of shaft portion 120serves to increase the area of rivet 112 exposed to the water. Headportion 122 illustratively has an outer diameter that approximates theouter diameter of pad 114. As illustrated in FIGS. 5-7, an o-ring seal116 is received by shaft portion 120 of rivet 112. Seal 116 is seated inan opening 124 (FIG. 6) molded in an outer wall 118 of valve housing 70.As such, seal 116 provides a sealed interface between heat transferdevice 110 and wall 118 to reduce the likelihood of water from valvehousing 70 leaking past heat transfer device 110. Head portion 122 abutswall 118 of valve housing 70 to hold seal 116 within opening 124, asillustrated in FIG. 7. Rivet 112 transfers heat from fluid adjacenthollow shaft portion 120 to head portion 122 and to pad 114, and pad 114transfers the heat to temperature sensor 54 on circuit board 40.Temperature sensor 54 outputs a signal representative of the detectedheat to processor 42 for processing. In one embodiment, rivet 112 iscoupled to wall 118 of valve housing 70 with an adhesive or anothersuitable fastener.

Processor 42 is operative to control faucet 10 based on the watertemperature measured with temperature sensor 54. In one embodiment,processor 42 is operative to selectively control light devices 59 (FIG.2) to illuminate different colored devices 59 to indicate the watertemperature to the user. For example, blue indicates cold water, redindicates hot water, and shades between red and blue indicatetemperatures between hot and cold. Alternatively, processor 42 displaysthe water temperature numerically on a digital or analog display (e.g.,an LCD display of indicator 29). In one embodiment, controller 24 isprogrammed to shut off water flow, i.e., close solenoid valve 22,automatically upon the detected water temperature exceeding a thresholdtemperature. An exemplary threshold temperature is about 120 degreesFahrenheit, although other suitable thresholds may be set. In oneembodiment, controller 42 uses the temperature information from sensor54 to control an electrically operable mixing valve (e.g., valve 20) inseries with solenoid valve 22. The mixing valve is controlled to mixwater proportionally from hot and cold sources 16, 18 to achieve adesired temperature. The desired temperature may be selectable by theuser or may be predetermined and programmed in memory of processor 42.As such, closed loop temperature control of the water through faucet 10may be provided with temperature sensor 54. Other suitable controls maybe implemented based on water temperature.

As illustrated in FIGS. 5 and 6, a solenoid coil 80 of solenoid valve 22includes coil wire 82 wound around a bobbin 84. Bobbin 84 includes acylindrical inner opening 86 sized to receive a cylindrical portion 94of valve housing 70. In the illustrated embodiment, solenoid coil 80 ismounted directly to circuit board 40 (see FIGS. 4 and 7-9). Inparticular, bobbin 84 includes a plurality of metal pins 88 that arereceived through corresponding openings 89 of circuit board 40. In oneembodiment, conductive pins 88 are soldered to circuit board 40. Ends ofcoil wire 82 are terminated at pins 88 (e.g., wound around pins 88) suchthat controller 24 is operative to selectively energize and de-energizecoil 80 via pins 88.

In one embodiment, bobbin 84 is made of plastic or another suitablenonconductive material. As illustrated in FIG. 7, ends 96 of bobbin 84are configured to abut circuit board 40. Circuit board 40 isillustratively parallel to the opening 86 extending through solenoidcoil 80. In one embodiment, with solenoid coil 80 mounted directly tocircuit board 40, a compact valve assembly 50 with minimal wiring isprovided with the controller 24 located inside outer housing 60.

Referring still to FIGS. 5 and 6, bobbin 84 slides over cylindricalportion 94 of valve housing 70 to couple solenoid coil 80 to valvehousing 70. In the illustrated embodiment, a circumferential lip orflange 97 (FIG. 8) of cylindrical portion 94 engages a correspondinggroove formed in the top surface of bobbin 84 to secure bobbin 84 tocylindrical portion 94. Valve housing 70, including cylindrical portion94, is made of plastic or another suitable electrically and magneticallyinsulating material. A U-shaped metal bracket 90 is sized to fit oversolenoid coil 80. Metal bracket 90 includes a bottom flange 98 having anopening 92 sized to receive cylindrical portion 94. As such, flange 98is positioned between solenoid coil 80 and a top wall 102 of valvehousing 70. A top flange 100 of bracket 90 slides over the top ofsolenoid coil 80. As such, metal bracket 90 extends along three sides ofsolenoid coil 80. As described herein, metal bracket 90 serves as acomponent for routing magnetic flux generated with solenoid coil 80. Inparticular, when solenoid coil 80 is energized by controller 24, bracket90 provides a flow path for the generated magnetic flux.

Referring to FIGS. 7-9, solenoid valve 22 further includes a permanentmagnet 140, a moveable valve member or armature 142, a fixed member orpole piece 144, an armature seal 146, a diaphragm housing 156, and aflexible diaphragm 158. Armature 142 and pole piece 144 are wetted andsealed within the hollow interior of cylindrical portion 94. Armatureseal 146 is coupled to an end of armature 142 and is configured to seala pilot hole 150 (FIGS. 8 and 9) formed in diaphragm housing 156. In oneembodiment, armature seal 146 is made of rubber, and armature 142 andpole piece 144 are made of metal or another suitable magneticallyconductive material.

Armature 142 is operably coupled to solenoid coil 80. In particular, themagnetic field generated with coil 80 is configured to move armature 142between a closed position and an open position. Armature 142, alsoreferred to as a plunger or moveable core, is configured to slide withincylindrical portion 94 between the closed position in contact with apilot hole seat 152 (FIGS. 8 and 9) and the open position in contactwith pole piece 144. When armature 142 is in the closed position,armature seal 146 engages pilot hole seat 152 to close pilot hole 150,and a gap is formed between armature 142 and pole piece 144. Whenarmature 142 is in the open position, the gap between armature 142 andpole piece 144 is closed and water flows through the open pilot hole 150and through an outlet 154 (FIGS. 8 and 9) formed in valve housing 70. Aspring 148 within cylindrical portion 94 biases armature 142 away frompole piece 144 and towards pilot hole seat 152. In the illustratedembodiment, armature 142 moves within cylindrical portion 94 along anaxis that is parallel to circuit board 40. An o-ring seal 138 (FIG. 8)is positioned between diaphragm housing 156 and wall 102 of valvehousing 70 to form a sealing surface surrounding the interface betweenarmature seal 146 and pilot hole 150.

Permanent magnet 140 is positioned in a seat 95 formed in the top ofcylindrical portion 94. Magnet 140 serves as a latching magnet to holdarmature 142 against pole piece 144 in the open position. In particular,permanent magnet 140 is sized and spaced relative to armature 142 andpole piece 144 such that when armature 142 is in the closed position,the magnetic field induced in pole piece 144 by magnet 140 is not strongenough to overcome the opposing biasing force provided by spring 148 dueto the gap between armature 142 and pole piece 144. After coil 80 isenergized to move armature 142 to the open position against pole piece144, the magnetic field induced by magnet 140 in pole piece 144 isoperative to overcome the opposing biasing force of spring 148 to latchor hold armature 142 in the open position after coil 80 is de-energized.

As illustrated in FIG. 7, fluid conduit 28 c is coupled to valve housing70 via a threaded interface 160 and forms a part of valve housing 70 todefine interior region 130. An o-ring seal 162 is positioned betweenvalve housing 70 and fluid conduit 28 c to facilitate sealing the waterwithin valve housing 70 at interface 160. Fluid conduit 28 c provides apassageway 164 in fluid communication with interior region 130 of valvehousing 70. Flexible diaphragm 158 is positioned within diaphragmhousing 156. In one embodiment, diaphragm 158 is made of flexiblerubber. An upper diaphragm chamber 166 is formed between diaphragmhousing 156 and the back side of diaphragm 158. When diaphragm chamber166 is flooded, water pressure in diaphragm chamber 166 forces diaphragm158 into a closed position such that diaphragm 158 abuts and seals acircumferential lip or bead 128 (FIG. 8) of conduit 28 c. As such, waterfrom passageway 164 is prevented from entering interior region 130 ofvalve housing 70 past circumferential lip 128 when diaphragm 158 is inthe closed position. In addition, diaphragm 158, when closed, provides acircumferential seal around a center post 170 (FIG. 8) of diaphragmhousing 156 to close an inlet 168 formed in a notch of post 170.

Solenoid valve 22 is illustratively a pilot operated solenoid valve.Before an initial use of solenoid valve assembly 50, diaphragm chamber166 is empty of water. When water is initially routed towards the frontside of diaphragm 158 via conduit 28 c, the center portion of diaphragm158 (near post 170) collapses or flexes upwardly (as viewed from theperspective of FIGS. 7-10) and the water enters diaphragm chamber 166through the opened inlet 168 formed in post 170. With coil 80de-energized and armature 142 in the closed position, the water floodsdiaphragm chamber 166. Some water also flows between lip 128 anddiaphragm 158 into the surrounding interior region 130 of valve housing70. Diaphragm chamber 166 illustratively occupies a larger area on theback side of diaphragm 158 as compared to the area occupied bypassageway 164 on the front side of diaphragm 158 within lip 128. Whenthe water pressure at the back side (the chamber 166 side) of diaphragm158 becomes greater than the water pressure at the front side (thepassageway 164 side) of diaphragm 158 due to the greater area diaphragmchamber 166, diaphragm 158 is forced back into the closed position toseal off inlet 168 and to seal off circumferential lip 128. As such,diaphragm 158 is in the closed position and diaphragm chamber 166 isfilled with water prior to energizing solenoid coil 80.

In operation, controller 24 energizes solenoid coil 80 upon detecting auser's hands via capacitive sensor 26 (FIG. 1) to turn on faucet 10.Energizing solenoid coil 80 with electrical current is operative toinitiate the pilot control of solenoid valve 22 to thereby open solenoidvalve 22. In particular, when coil 80 is energized, the generatedmagnetic flux magnetizes armature 142 and pole piece 144 to causearmature 142 and pole piece 144 to be attracted to each other. Themagnetic field moves armature 142 into contact with pole piece 144 inthe open position to close the gap between armature 142 and pole piece144 and to open pilot hole 150. In the illustrated embodiment,controller 24 de-energizes coil 80 after a predetermined duration, andthe magnetic field induced by permanent magnet 140 in pole piece 144holds armature 142 in the open position against pole piece 144, asdescribed herein. Alternatively, solenoid coil 80 may remain energizedwhile faucet 10 is on to hold armature 142 in the open position.

With armature 142 in the open position (see FIG. 9), water in upperdiaphragm chamber 166 moves through a channel 180 in valve housing 70and exits through the opened pilot hole 150. The water through pilothole 150 exits through an outlet 154 which opens into the interiorchamber 130 (FIG. 7) of valve housing 70. With the water pressurereduced on the back side of diaphragm 158 in chamber 166, diaphragm 158collapses and opens solenoid valve 22 such that water from passageway164 flows between diaphragm 158 and lip 128 into the surroundinginterior region 130 of valve housing 70. Water in the interior region130 moves through a passageway 172 (FIG. 10) formed in fluid conduit 28d and exits spout 12 (FIG. 1) of faucet 10.

When controller 24 no longer detects the user's hands via capacitivesensor 26 (and/or after a suitable delay), controller 24 energizessolenoid coil 80 with a reverse current to disrupt the magnetic field ofmagnet 140 that holds armature 142 in the open position. In particular,energized coil 80 induces a magnetic field in armature 142 and polepiece 144 having an opposite polarity as the magnetic field induced bypermanent magnet 140, thereby cancelling the attraction between polepiece 144 and armature 142. As such, the opposite polarity magneticfield and the biasing force of spring 148 force armature 142 back to theclosed position against seat 152 to close pilot hole 150. With pilothole 150 closed, diaphragm chamber 166 is re-flooded to force diaphragm158 to the closed position against lip 128. As a result, solenoid valve22 is closed and water flow through spout 12 is stopped.

In one embodiment, the force required to collapse diaphragm 158 to opensolenoid valve 22 is small due to the small size of pilot hole 150relative to the valve opening between diaphragm 158 and lips 128. In oneembodiment, inlet 168 formed in the notch of post 170 of diaphragmhousing 156 serves to bleed water slowly into diaphragm chamber 166 whenclosing solenoid valve 22, thereby providing a soft shutoff for faucet10. In one embodiment, inlet 168 also serves as a filter to blockparticles in passageway 164 from entering diaphragm chamber 166, therebyimproving the cleanliness of the area within diaphragm chamber 166.

In one embodiment, controller 24 is operative to control solenoid valve22 further based on output from flow sensor 52 of FIG. 2. For example,in one embodiment controller 24 controls solenoid valve 22 to dispense apredetermined volume of water before automatically shutting off faucet10. In another example, controller 24 may control the flow of waterthrough spout 12 to a desired flow rate either specified by the user orset by the manufacturer. In another example, controller 24 detects amalfunction of faucet 10 based on an improper flow rate through spout12. Other suitable controls may be implemented based on flow sensor 52.Flow sensor 52 may include an impeller positioned in the flow path(e.g., in fluid conduit 28 d) and a Hall effect sensor coupled tocircuit board 40 that detects the position of the impeller to track flowcapacity through fluid conduit 28 d. Other suitable flow sensors 52 maybe provided.

In one embodiment, auxiliary port 56 is configured to connect an inputdevice to controller 24. The input device may route control and/orfeedback signals to controller 24 used to control faucet 10. Anexemplary input device includes a foot switch or a microphone. In oneembodiment, controller 24 receives inputs from a foot switch viaauxiliary port 56 and controls faucet 10 based on the foot switchinputs. For example, a foot switch may be positioned below the sinkbasin. Upon actuation by a user, the foot switch sends a signal tocontroller 24 via auxiliary port 56 instructing controller 24 to turn onor off faucet 10 or to adjust the flow rate or temperature of the fluid.In another embodiment, controller 24 powers and controls a plurality oflight devices (e.g., LED's) positioned around the sink basin viaauxiliary port 56. In another embodiment, a microphone is operablyconnected to auxiliary port 56 of controller 24 to provide voiceactivation of faucet 10. For example, controller 24 detects audiblesignals (e.g., a user's voice) through the microphone and controlsfaucet 10 based on the audible signals. Exemplary voice activatedcontrols include on/off, flow rate, and water temperature.

U.S. Pat. No. 8,944,105; U.S. Pat. No. 8,613,419; U.S. Pat. No.8,561,626; and U.S. Pat. No. 9,187,884, are expressly incorporated byreference herein.

Although the invention has been described in detail with reference tocertain preferred embodiments, variations and modifications exist withinthe spirit and scope of the invention as described and defined in thefollowing claims.

1. An electronic faucet comprising: a spout; a fluid supply conduitsupported by the spout; a valve assembly including an electricallyoperable valve in fluid communication with the fluid supply conduit; anda controller coupled to the valve assembly and including a processoroperative to control the electrically operable valve to control fluidflow through the fluid supply conduit, the controller including a portin communication with the processor, the port being releasably coupledto electronics of a secondary device to provide communication betweenthe controller and the electronics of the secondary device.
 2. Thefaucet of claim 1, wherein the controller is operative to at least oneof control or power the electronics of the secondary device via theport.
 3. The faucet of claim 2, wherein the processor is operative tocontrol an electrically operable valve of the secondary device via theport to control fluid flow through the secondary device.
 4. The faucetof claim 3, wherein the processor is operative to receive input signalsfrom a proximity sensor of the secondary device via the port and tooutput electrical control signals to the secondary device via the portto control the electrically operable valve of the secondary device basedon the input signals.
 5. The faucet of claim 2, further including anelectrical cable routed from the port to the electronics of thesecondary device to route control signals from the controller of theelectronic faucet to the electronics of the secondary device, theelectrical cable including a connector that is releasably coupled to theport.
 6. The faucet of claim 2, wherein the controller is operablycoupled to a power source for powering the electronic faucet, and thecontroller powers the electronics of the secondary device from the powersource via the port.
 7. The faucet of claim 1, wherein the secondarydevice includes at least one of a soap dispenser or a beveragedispenser.
 8. The faucet of claim 1, wherein the secondary deviceincludes an electronic faucet.
 9. The faucet of claim 1, wherein thesecondary device comprises an input device to provide signals to thecontroller.
 10. The faucet of claim 9, wherein the input device includesa microphone.
 11. The faucet of claim 1, wherein the controller includesa printed circuit board coupled to the valve assembly, and the processorand the port are mounted to the printed circuit board.
 12. The faucet ofclaim 11, wherein the valve assembly includes an outer housing having anopening, the printed circuit board and the electrically operable valveare positioned in the outer housing, and the port is accessible throughthe opening of the outer housing.
 13. A faucet system including: anelectronic faucet including a spout, a fluid supply conduit supported bythe spout, a valve assembly having an electrically operable valve influid communication with the fluid supply conduit, and a controlleroperative to control the electrically operable valve to control fluidflow through the fluid supply conduit, the controller including a port,the controller and the port being mounted to the valve assembly; and asecondary dispensing device including a spout, a fluid supply conduitsupported by the spout, and electronics operably coupled to the port ofthe controller of the electronic faucet, the controller being operativeto at least one of control or power the electronics of the secondarydispensing device via the port to control fluid flow through the fluidsupply conduit of the secondary dispensing device.
 14. The faucet systemof claim 13, wherein the electronics include an electrically operablevalve positioned to regulate fluid flow through the fluid supply conduitof the secondary dispensing device.
 15. The faucet system of claim 14,wherein the secondary dispensing device includes a proximity sensorconfigured to detect an object near the spout of the secondarydispensing device and to transmit a detection signal to the controllerthrough the port, and the controller is operative to control theelectrically operable valve of the secondary dispensing device based onthe detection signal.
 16. The faucet system of claim 15, wherein theproximity sensor includes a capacitive touch sensor operative to detectan object contacting the spout of the secondary dispensing device. 17.The faucet system of claim 13, further including an electrical cablerouted from the port of the controller to the electronics of thesecondary dispensing device to route power and control signals from thecontroller of the electronic faucet to the electronics of the secondarydispensing device, the electrical cable including a connector that isreleasably coupled to the port.
 18. The faucet system of claim 17,wherein the controller includes a printed circuit board coupled to thevalve assembly, and the processor and the port are mounted to theprinted circuit board.
 19. The faucet system of claim 18, wherein thevalve assembly includes an outer housing having an opening, the printedcircuit board and the electrically operable valve are positioned in theouter housing, and the port is accessible through the opening of theouter housing.
 20. The faucet system of claim 13, wherein the controlleris operably coupled to a power source for powering the electronicfaucet, and the controller powers the electronics of the secondarydispensing device from the power source via the port.
 21. The faucetsystem of claim 13, wherein the secondary dispensing device includes atleast one of a soap dispenser or a beverage dispenser.
 22. The faucetsystem of claim 13, wherein the secondary dispensing device includes anelectronic faucet.
 23. An electrically operable valve assembly for anelectronic faucet comprising: a valve housing including an interiorregion for receiving a fluid; a solenoid valve; a temperature sensorpositioned outside the interior region; a heat transfer device extendingbetween the temperature sensor and the interior region to transfer heatfrom fluid in the interior region to the temperature sensor; acontroller in communication with the temperature sensor and operative tocontrol the solenoid valve; and an electronically controlled valve bodyassembly in series with the solenoid valve and controlled by thecontroller to control the temperature of fluid within the interiorregion in response to input from the temperature sensor.
 24. Theelectrically operable valve of claim 23, wherein the controller includesan electronic circuit board coupled to the valve housing, and thetemperature sensor is mounted to the electronic circuit board.
 25. Theelectrically operable valve of claim 24, wherein the electronic circuitboard and the temperature sensor are positioned outside of the valvehousing.
 26. The electrically operable valve of claim 23, wherein thevalve housing includes an outer wall defining the interior region, andthe heat transfer device extends into the interior region through anopening formed in the outer wall.
 27. The electrically operable valve ofclaim 26, further including an o-ring seal positioned in the openingbetween the heat transfer device and the outer wall of the valvehousing.
 28. The electrically operable valve of claim 23, wherein theheat transfer device includes a rivet, the rivet includes a hollow shaftportion and a head portion, and the hollow shaft portion is configuredto receive fluid from the interior region of the valve housing.
 29. Theelectrically operable valve of claim 28, wherein the heat transferdevice further includes a thermally conductive pad positioned betweenthe rivet and the temperature sensor for transferring heat from therivet to the temperature sensor.
 30. The electrically operable valve ofclaim 23, wherein the controller is operative to control the solenoidvalve based on output from the temperature sensor.
 31. The electricallyoperable valve of claim 23, wherein the temperature sensor includes athermistor.
 32. The electrically operable valve of claim 23, wherein:the solenoid valve includes a solenoid coil and a moveable valve memberoperably coupled to the solenoid coil; and the controller includes anelectronic circuit board coupled to the valve housing, and a processormounted to the electronic circuit board to control the solenoid valve,the solenoid coil being mounted to the circuit board.
 33. Theelectrically operable valve of claim 32, wherein the solenoid coilincludes at least one conductive element, the solenoid coil beingdirectly mounted to the electronic circuit board by way of the at leastone conductive element being received by at least one opening in theelectronic circuit board.
 34. The electrically operable valve of claim23, further comprising a detection sensor operative to provide a signalto the controller, the controller being operative to at least one ofopen and close the solenoid valve based on the signal provided by thedetection sensor.
 35. The electrically operable valve of claim 32,wherein the controller includes a port in communication with theprocessor, the port being releasably coupled to electronics of asecondary device.